Resinous reaction products



Patented RESINOUS REACTION PRODUCTS Harry L. Allen, Philadelphia, Pa, and Earl G. Kerr, Haddonfield, N. 3., assignors to Allied Chemical & Dye Corporation, New York, N. Y., a corporation of New York No Drawing. Application October 31, 1945,

Serial No. 625,958

- 13 Claims. (Cl. 26043) i 2 This invention relates to a process of producduring the coking of coal, distillation of coal tar ing novel "two-stage thermosetting resins. and water gas tar, or may be collected in coal t 18 an O j of t invention to provide novel gas and water gas distribution systems. Solvent "two-stage -thermosetting resinous reaction naphtha, coke oven light oil, drip oil, and water products of coumarone, indene and their homo- 5 gas tar distillates are representative of such oils. logs with phenol and formaldehyde. Fractions of such oils boiling within the range of It is another object of the invention to provide 150 to 210 C. may be employed. Such fractions a, novel thermoplastic resin product which may contain a varying but substantial amount of inbe cured to insoluble, infusible state by heating in dene, coumarone, or their homologs, and ordithe presence of lime and hexamethylenetetral0 narily contain mixtures of two or more of such mine. It is a further object of the invention to compounds, the proportions of these polymerizaprovide a process for the manufacture of such ble materials depending on the source of the oil resins. Other objects and advantages'will appear and the boiling range of the fraction. For exhereinafter. ample, fractions of extracted carbolic oils boiling The first-stage thermoplastic resins of the inwithin the range of 150 to 210 C. ordinarily convention are made by reacting together one or tain indene as the chief polymerizable constitumore polymerizabl materials of the group conent; fractions of light oil residues boiling within sisting of coumarone, indene and their homologs, the range of 150 to 210 C. are rich in indene phenol in amount at least equal to the weight of and contain less coumarone. Such oils, particuthe polymerizable material, formaldehyde and an larly drip oil fractions, may also contain other acid polymerization catalyst, preferably sulfuric polymerizable materials such as methylstyrene acid. When the reaction is complete, the reaction in amount less than the coumarone-indene conmixture is distilled to recover as distillation resitent of the fractions. Preferably, however, we due the thermoplastic resinous reaction product employ a fraction or blend of oils containing inof the poiymerizable material, phenol and formdene and a smaller amount (by weight) of styrene aldehyde. than indene. for example, a drip oil fraction boil- The resinous products of the first-stage of this ing within the range of 130 to 210? C., or a blend invention may be compounded with hardening of the styrene fraction of drip oil boiling-within agents such as alkali and hexamethylenetetrathe range of 130 .to 160 C. with a suflicient mine to produce two-stage resins and the reamount of indene fraction of coal tar oil boiling sultant compounds are converted to insoluble, within the range of 150 to 210 C. so that the infusible masses when further compounded with blend contains a greater proportion of indene fillers, lubricants, and dyes and subjected to heat than styrene. Such styrene-containing fractions and pressure. They are well adapted for molding and blends produce more rapidly curing resins and produce molded articles having an excellent, than styrene-free oils. smooth molded. surface and good mechanical and As the phenolic reagent, substantially pure dielectric properties. The two-stage resins are phenol or blends of phenol with minor amounts also suitable thermosetting binders for use in the of cresols and xylenols are employed. For exproduction of laminated products by impregnatample, blends of phenol with up to 40% by weight ing and laminating sheets of fibrous material such 40 of meta-para cresol may be employed to obtain as textile fabrics, paper, etc., and may be emthe thermoplastic resinous products of the inployed in the manufacture of tubing and coatvention. In order to obtain resins which are ings. In general, the time required for effecting converted to insoluble, infusible products when cure of the resins at a given temperature demixed with alkali such as lime and hardening pends on the relative proportions of coumaroneagents such as hexamethylene-tetra'mine and subindene type polymerizable material present, i. e. iected to the influence of heat, it is important the higher the ratio of coumarone-indene polythat the reaction mixture contain an amountof merizable material to phenolic material the longphenol by weight at least equal to the amount of er the time required to cure the resin. Thus, by polymerizable material employed. Preferably, varying the proportions of phenolic material and the weight ratio of phenol to polymerizable' mapolymerizable material, resins suitable for varterial falls within the range of 3:2 to 10:1.

ious purposes for which varying rates of cure are In order to obtain thermoplastic resins, it is desirable may be readily obtained. also important to carry out the reaction between Oil fractions containing paracoumarone resinthe phenol, formaldehyde and polymerizable maforming polymerizable constituents such as are. terial in the presence of an acid catalyst. The

employed in the production of paracoumarone preferred catalyst is sulfuric acid; phosphoric resin are preferably utilized as the source of polyacid and hydrochloric acid may also be employed.

merizable material in carrying out the invention. The formaldehyde may be employed in any Such oils are formed in the distillation of coal desired form; preferably, commercially availand carburetion of water gas and are obtained able aqueous formaldehyde solutions are utilized.

dure.

Gaseous anhydrous formaldehyde and paraformaldehyde are also suitable and are included within the scope of the term formaldehyde as used herein. The formaldehyde is employed in molar amount less than the combined molar amounts of phenol and polymerizable material. The amount of formaldehyde employed is ordinarily from 0.70 to 0.95, preferably from 0.80 to 0.90 mol for each mol of phenol and polymerizable material introduced into the reaction mixture.

The invention may be carried out by introducing the polymerizable material, phenol and formaldehyde into a reaction vessel, heating the reaction mixture to a temperature of at least 65 0., preferably 65-90 C., and adding the catalyst to the heated mixture; addition of the catalyst after the other reactants have been heated-above 85 C. produces more rapidly curable resin than is obtained when all of the constituents of the reaction mixture are mixed at room temperature, and is the preferred proce- The reaction then proceeds under the influence of the liberated heat without further external heating, causing the temperature of the mixture to rise to within the range 95 to 100 C. The temperature is maintained within this range, while agitating the reaction mixture, until the 'reaction is complete. If the reaction tends to proceed too vigorously, the reaction mixture may be cooled to prevent the temperature from rising above 100 C. It is desirable to prevent the temperature from rising above 102 C., as higher temperatures promote excessive foaming of the reaction mixture and also deleteriously aifect the properties of the resin. Maintenance of the temperature within the range of 95 to 100 C. for from 1 to 3 hours is ordinarily sufficient to complete the reaction. When the reaction is complete, the reaction mixture is distilled, preferably under vacuum, e. g. absolute pressure 'of a coal tar oil fraction having a distillation range of 172 to 193 C. containing 53.3% by weight (20 parts) ofpolymerizable material, chiefly indene, and about 2.15 parts of sulfuric acid of 20% concentration were charged into a. steamjacketed reaction vessel equipped with agitator. The mol ratio of formaldehyde to the phenol and polymerizable material was about .91:1. Steam was passed through the jacket while agitating the'contents of the vessel until the temperature of the reaction mixture rose to 90 C. and the passage of steam was then discontinued. The temperature of the reaction mixture rose under the influence of the heat liberated during the reaction to 96 C. and was maintained at about 96 C. for 2 hours, at the end of which time the reaction was complete. The contents of the reaction vessel were agitated throughout the reaction. The reaction mixture was then subjected to distillation under absolute pressure of 3" of mercury and the distillation continued reached 160 C. a melting point of 117 C. were obtained as residue. The resin had a color of 07, an acid numstantially complete.

. 4 ber of 6.5, was insoluble in benzene and dryi oils, and soluble in ethyl alcohol and in a mixture of equal parts by weight of ethyl alcohol and benzene.

Example 2.70 parts of phenol, 75 parts of 37% aqueous formaldehyde solution, 57 parts of the coal tar oil fraction employed in Example 1 (containing 30 parts of polymerizable material, chiefly indene), and about 2.26 parts of sulfuric acid of 20% concentration were charged into a reaction vessel similar to that employed in Example 1. The mol ratio of formaldehyde to the phenol and polymerizable material was .93:1. The contents of the reaction vessel were heated to 90 C. by passing steam through the jacket while agitating, the passage of steam was then discontinued and the temperature of the reaction mixture rose to 96 C. under the influence of the heat liberated during the reaction and this temperature was maintained for about, 3 hours, at the end of which time the reaction was sub- The reaction mixture was distilled under absolute pressure of 3 of mercury until the temperature of the resin reachedv 148 C. 104.5 parts of resin of a melting point of 143 C. were obtained as residue. The resin had a color of C5, an acid number of 3.5, was insoluble in benzene and drying oils, and soluble in ethyl alcohol and a mixture of equal parts by weight of ethyl alcohol and benzene.

Example 3.-60 parts of phenol, 75 parts of 37% aqueous formaldehyde solution, 76 parts of the coal tar fraction employed in Example 1 (containing 40 parts of polymerizable material, chiefly indene), and 2.52 parts of sulfuric acid of 20% concentration were charged into a reaction vessel similar to that employed in Example 1. The mol ratio of formaldehyde to the phenol and polymerizable material was .95:1. The contents of the reaction vessel were heated to 90 C. by passage of steam through the jacket of the vessel and the passage of steam was then discontinued. The temperature of the reaction mixture rose under the influence of heat liberated during the reaction to 96 C. after the passage of steam was discontinued and was maintained at about 96 C. for 2% hours, at the end of which time the reaction was substantially. complete. The reaction mixture was then subjected to distillation under absolute pressure of 3" of mercury and the distillation was continued until the temalcohol and a mixture of equal parts by weight g of ethyl alcohol and benzene.

The thermoplastic resins of Examples 1, 2 and 3 were compounded in accordance with the following formulae, parts being given by weight:

Com- Com- Com- Compound pound pound pound Resin of Example 1 44. 25 37. 17 Basin of Example 43. 87 36. 85 Hexamethylene tetramine 4. 45 3. 72 4. 82 4. 05 Wood flour 44 53 44 53 Diatomaeeous earth. 3 2 3 2 2 2 2 .2 0. 75 0. 66 0. 79 0. 66 1 l l 1 0. 55 0. 45 0. 52 0. 44

Oomp ouud Oomgound Example 4 Example 5 nesmrommmplea 43 50 g M160 0. at 170 0. at 100 0. at 110 0. Hoxamcthylene tetra mini: 6:1) I 6.36 5 good flournnag nn 4g 5; Time (seconds) Time (seconds) 8 OIDBOBOUS 6 Dye it '2 Montan wax 0.78 0.66 S g 9 7 i4 11 Lubricant. 1 1 Silk 1s 15 2c 25- Llme I 0.52 0.44 (lure 31 2o 65 30 The diatomaceous earth was a filler sold under p es 6 n 'i-' o reaction mixtures the trade-name "Celite." The lubricant was calwere made up as cium stearate.

The ingredients of the above compounds were Examplofi Example 1 assembled, milled on diflerential rolls at mill-roll temperatures between 230 and 300 1'. until the C gg f2; 2% ingredients were thoroughly mixed. The comif il h ifl hi "igfg pounds were then sheeted and ground to fine formaldehyde-W 203 molding powders. The molding powders had ap- 20 smut:

parent densities ranging from about .45 for compound 6 to .65 for compound 1. powders were placed in molds and cured at 170 C. under pressure of 4500 pounds per square inch. The time required to cure discs thick and '4" in diameter varied from about 2 to 3% minutes. The time required to shoot cure may be reduced by preheating the molded compounds, e. g. to a temperature of 125 C. for minutes.

The molded products had an excellent, smooth molded surface. Their specific gravity was from 1.33 to 1.44 (A. S. T. M. method D571-27). The molded products were subjected to water absorptlon, acetone extraction; shrinkage, heat distortion, hot oil and oven bake tests, and were also tested for hexural strength, impact strength, tensile strength, .compressive strength, and dielectric strength by the customary methods ap- The molding plied to phenol-formaldehyde resins. The results of the tests indicate that the products may be satisfactorily employed for the general purposes for which phenol-formaldehyde thermosetting resins areutilized.

,Examples 4 and 5.- Two reaction mixtures were made up as follows:

The coal tar fraction was an oil distillate boiling within the range of 169,.5 to 196, C. and

' contained about 60% by weight of polymerizable material, chiefly indene and coumarone. The reactants were heated together in reaction vessels until the mixtures reached a temprature of 70 C., after which the temperature rose to 96 C. under the influence of the heat liberated during the reaction and was maintained at this point for 1 hour while agitating the contents of the vessels. The two reaction mixtures were then vacuum distilled under absolute pressure of 5" of mercury for 2 and 1% hours, respectively. 324 parts of resin of a melting point of 138 C. were recovered in Example 4 and 311 parts of resin of a melting point of 125. C. were recovered in Erbample 5.

The resins of Examples 4 and 5 were subjected to curing tests on a hot plate at 160 and 170 C... and the times required for the resinsto reach string," "silk and cured conditions were noted. The results of the tests were as follows:

The carbolic oil hiflash was a coke oven tar distillate boiling within the range of 152 to.203 C. and contained about 53% by weight of polymerlzable compounds, chiefly indene and coumarone. The drip oil hifiash boiled within the range of 160.5" to 205 C. and contained 45.3% of polymerizable compounds, chiefly indene. The reaction mixtures were reacted for 1 hours at 96 C. and then vacuum distilled under absolute pressure of 4" of mercury until the temperature of the resin rose to 144 and 141 C., respectively. 305 parts of thermosetting resin of C5 col-or and 131 C. melting point were recovered in Example 6 and 316 parts of thermoplastic resin of C11 color and 135 C. melting point were recovered in Example 7.

Carbolic oil hiflash similar to that employed in Example 6 was fractionated to obtain a cut boiling at from 169 to 179 C. which contained about 45% of polymerizable material, largely coumarone, and another cut boiling at 179 to 183 C. which contained about 72% of polymerizable material, largely indene. Resins made in accordance with the foregoing examples, employing these cuts as the source of coumarone and indene, resulted in first-stage thermoplastic resins resembling those of the examples.

Example 8.-300 parts of phenol, 270 parts of 37% aqueous formaldehyde solution, '72 parts of carbolic oil fraction boiling within the range of 175 to 185 C. (containing 50 parts of polyme'rizable material, chiefly indene), and 250 parts of a dripoil fraction boiling within the range of 130 to 160 C. (containing 50 parts of styrene), were charged into a-reaction vessel and heated to about C. 22.8 parts of sulfuric acid polymerization catalyst of 20% concentration were added to the vessel, after which the temperature of the mixture rose to to C. and was maintained within this rangefor 1 hour. The reaction mixture was then subjected to 1 distillation under vacuum to recover the resinousreaction product as residue. This resin produced molded products similar to those produced by the resins of the preceding examples when comtogether polymerizable materials of the coumarone-indene type, phenol and formaldehyde. The resins are admirably adapted for molding under heat and pressure form molded articles and are also suitable for use in laminating fibrous material such as paper and textile fabrics. Since the rate of cure of the resins may be varied by varying the proportions of phenol and polymerizable material, it is possible. to make resins for difierent purposes requiring difierent rates of cure. Owing to the fact that coumarone-indene type polymerizable materials are considerably less costly than phenol, the resins of the invention are less expensive to manufacture than phenol-formaldehyde resins.

The resin melting points given herein were determined by the cube-in-mercury method described in Protective and Decorative Coatings, vol. 1, pages 366-367, by J. J. Matiello, copyright 1941, published by John A. Wiley a Sons, Inc.,

New York, New York. Resin colors were determined by the color scale disclosed in Cline United States 'iatent No. 2,344,676 of March 21, 1944.

Since certain changes may be made without departing from the scope of the invention, it is intended that the above description shall be interpreted as illustrative and not in a limiting sense.

We claim:

1. A process for producing thermoplastic resins which comprises heating together at a temperatime between 65 and 102 C. an oil containing as its major polymerizable constituent at least one polymerizable material of the group consisting of coumarone, indene and their homologs boiling below 210 C.; a phenolic reagent of the group consisting of phenol, mixtures thereof with minor proportions of cresols and mixtures thereof with minor proportions of xylenols; and 0.70 to 0.95 mol of formaldehyde for each mol of phenolic reagent and total polymerizable material, in the presence of an acid catalyst of the group consisting of sulfuric acid, phosphoric acid and hydrochloric acid, the weight of total polymerizable material being equal to not less than nor more than 100% of the weight of said phenolic reagent in the mixture.

2. A process as defined in claim 1 in which the catalyst is sulfuric acid.

3. A process as defined in claim 1 in which the oil contains indene and styrene in amount less than the indene.

4. A process as defined in claim 1 in which the styrene in amount less than the indene and the catalyst is sulfuric acid.

5. A process as defined in claim 1 in which the reaction mixture is fractionally distilled to remove volatile oils, yielding as distillation residue a thermoplastic resin.

6. A process as defined in claim 5 in which the catalyst is sulfuric acid.

7. A process as defined in claim 6 in which the polymerizable material is composed substantially entirely of indene and styrene in amount less than the indene.

8. A process as defined in claim 7 in which the formaldehyde is present in amount equal to 0.8 to 0.9 mol for each mol of total polymerizable material.

9. A process as defined in claim 8 in which the oil contains indene and heating is efiected to raise the temperature to about C. before the sulfuric acid catalyst is added and the temperature is thereafter raised to within the range -100 C.

10. A thermoplastic resinous acid copoly merization product obtained by the process of claim. 9.

11. A molding powder comprising a comminuted inert filler, hexamethylene tetramine, lime and a thermoplastic resinous acid copolymerization'product obtained by the process of claim 10.

12. A thermoplastic resinous acid copolymerlzation product obtained by the process of claim 1.

.13. A molding powder comprising a comminuted inert filler, hexamethylene tetramine, lime and a thermoplastic resinous acid copolymerization product obtained by the process'of claim 1.

' HARRY L. ALLEN.

EARL G. KERR.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PA'I'ENTS Number Name Date 1,616,321 Kessler Feb. 1, 1927 2,050,188 Lee et al. Aug. 4, 1936 2,101,853 Harvey Dec. 14, 1937 2,114,121 Bender Apr. 12, 1938 7 2,198,318 Sachanen et al Apr. 23, 1940 

